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1981 GSX1100 Katana Based Project

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    #91
    DW engine painted 4 by Max Mutarn, on Flickr
    Badgezz, we don need noh stinkin' badgezz!
    Shin-Ken 1074
    1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
    1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

    Comment


      #92
      Stator, ignition, clutch, tappet and sprocket cases have been removed and being painted later. Cases will be installed with new gaskets when they are ready and some modifications are complete.

      DW engine painted 1 by Max Mutarn, on Flickr
      Badgezz, we don need noh stinkin' badgezz!
      Shin-Ken 1074
      1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
      1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

      Comment


        #93
        DW engine painted 5 by Max Mutarn, on Flickr
        Badgezz, we don need noh stinkin' badgezz!
        Shin-Ken 1074
        1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
        1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

        Comment


          #94
          DW engine painted 3 by Max Mutarn, on Flickr
          Badgezz, we don need noh stinkin' badgezz!
          Shin-Ken 1074
          1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
          1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

          Comment


            #95
            DW engine painted 6 by Max Mutarn, on Flickr
            Badgezz, we don need noh stinkin' badgezz!
            Shin-Ken 1074
            1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
            1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

            Comment


              #96
              Sprocket case after stitch drilling and file work between each of the cast gussets.

              DW sprocket case 1 by Max Mutarn, on Flickr
              Badgezz, we don need noh stinkin' badgezz!
              Shin-Ken 1074
              1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
              1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

              Comment


                #97
                DW sprocket case 2 by Max Mutarn, on Flickr
                Badgezz, we don need noh stinkin' badgezz!
                Shin-Ken 1074
                1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                Comment


                  #98
                  OEM sprocket case

                  DW sprocket case OEM by Max Mutarn, on Flickr
                  Badgezz, we don need noh stinkin' badgezz!
                  Shin-Ken 1074
                  1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                  1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                  Comment


                    #99
                    DW 180 modified sprocket case 486 grams lighter.

                    DW sprocket case 4 by Max Mutarn, on Flickr
                    Badgezz, we don need noh stinkin' badgezz!
                    Shin-Ken 1074
                    1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                    1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                    Comment


                      The EF stator case had a bit of road rash that needed some attention before painting, nothing serious, just not as tidy as it should be.

                      stator case 1 by Max Mutarn, on Flickr


                      stator case 2 by Max Mutarn, on Flickr

                      stator case 3 by Max Mutarn, on Flickr


                      stator case 6 by Max Mutarn, on Flickr


                      stator case 7 by Max Mutarn, on Flickr


                      stator case 11 by Max Mutarn, on Flickr
                      Last edited by Shin-Ken 1074; 09-27-2023, 03:16 AM.
                      Badgezz, we don need noh stinkin' badgezz!
                      Shin-Ken 1074
                      1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                      1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                      Comment


                        Where I can I like to change the profile of a part to reduce weight rather than the usual path of making parts into Swiss Cheese. It isn't always possible but when it is it can be a very subtle way to reduce weight.

                        Have replaced the OEM SZ steel rear brake pedal with an 1983 SD aluminium pedal and reshaped it using a file and fitting a titanium bolt.

                        This pic shows two SD aluminium brake pedals, left pedal is stock and right one is after reshaping.


                        DW v OEM brake pedal by Max Mutarn, on Flickr
                        Last edited by Shin-Ken 1074; 09-27-2023, 03:45 AM.
                        Badgezz, we don need noh stinkin' badgezz!
                        Shin-Ken 1074
                        1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                        1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                        Comment


                          OEM 1982 SZ steel brake pedal.

                          DW brake lever OEM by Max Mutarn, on Flickr

                          Modified OEM SD aluminium brake pedal.

                          DW ally brake pedal by Max Mutarn, on Flickr
                          Badgezz, we don need noh stinkin' badgezz!
                          Shin-Ken 1074
                          1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                          1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                          Comment


                            SZ OEM steel brake pivot.

                            OEM steel brake pivot by Max Mutarn, on Flickr


                            DW OEM brake pivot bored out 13mm.

                            DW hollow brake pivot by Max Mutarn, on Flickr

                            Badgezz, we don need noh stinkin' badgezz!
                            Shin-Ken 1074
                            1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                            1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                            Comment


                              At Last the tally moves. Tally = 96,299 grams.

                              DW rear brake 1 by Max Mutarn, on Flickr
                              Last edited by Shin-Ken 1074; 09-27-2023, 05:51 AM.
                              Badgezz, we don need noh stinkin' badgezz!
                              Shin-Ken 1074
                              1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                              1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                              Comment


                                OEM steel engine rear bolt spacer. Tally = 96,299 grams.

                                OEM rear engine bolt spacer by Max Mutarn, on Flickr

                                DW ally engine rear bolt spacer.

                                DW ally engine rear bolt spacer by Max Mutarn, on Flickr
                                Last edited by Shin-Ken 1074; 09-27-2023, 06:17 AM.
                                Badgezz, we don need noh stinkin' badgezz!
                                Shin-Ken 1074
                                1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                                1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                                Comment

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